Metal blank and method of forming same



March 29, 1932. J, TARBQX 1,851,023

METAL BLANK AND METHOD OF FORMING SAME Filed Feb. 6, 1930 INVENTOR.

Patented Mar. 29, 1932 i JOHN P. TARBOX, OF PHILADELPHIA, PENNSYLVANIA, ASSIGN'OR- TO EDWARD G. BUDD MANUFACTURING COMPANY, OF PHILADELPHIA, PENNSYLVANIA, A CORPORATION ANIA METAL BLANK AND METHOD OF FORMING SAME Application filed February 6, 1930. Serial No. 426,242.

The present invention relates to formable as will lend itself to the facilitative and efl'ecblanks in which portions of the material of tive formation by the said process. the blanks are drawn laterally to the main These objects are accomplished in a manbody thereof at an angle to each other and to ner as will hereinafter appear, and the inthe method of manufacturing such blanks. vention will now be described in connection In the employment of such blanks for com with the accompanying drawings illustrating struction purposes, considerable strain is an application of the invention to a vehicle placed on the material of the blanks at the body. In the drawings, juncture between the angularly related lat- Fig. 1 shows the blank of an automobile 1o erally drawn portions with a consequent body after having been drawn into shape. weakening and frequent breaking of the mate- Fig. 2 shows the initial formation of the rial at such junctures. This is particularly main body of the blank in the flat, with the true in the manufacture of metallic coup gusset juxtaposed thereto in the position for bodies in which draws of comparatively great initiation of welding. 15 depth are encountered at the juncture between Fig. 3 is a detail showing, in perspective the rear quarter of the body and the side of the gusset. panels of the deck. 1 ig. 4is aview showing the sections secured These problems have been solved for a wintogether, and constituting the completed dow frame construction by the invention disblank. 20 closed in the patent to G. W. Wells, No. In Fig.1is shown the side of an automobile 1,545,021, issued July 7, 1925, by the insertion coup, made from a single stamping. The of gussets in notches formed in a blank at the margins E at the rear quarter and the angle prospective juncture between flanges to be A between the top and the deck are deep laterally drawn into angular positions to each drawn, sometimes as much as five or six inches. 25 other, said gussets being of greater transverse y invention finds application at the angle 5 fullness than the width of the notches when to prevent splitting or creasing or other in blank and adapted when drawn over to fill irregularities. the space between the edges of the notches The main body of the blank 10 of the ine and complete the formation of the corners vention is cut from fiat stock to proper outwithout break or objectionable strain on the line, and simultaneously or subsequently 80 material of the frame. thereto, is formed recess or cut away 11. In Owing to the Construction of the notche f this recess is then secured the supplemental the Wells invention, it does not lend itself section 12 which has previously been cut to manufacture by flash welding processes from stock and shaped with a crease or fold I6 which is desirable under certain circumstances 13 adapted to be straightened out in drawing as where it is important to provide Wl h the blank into shape over a form. The edges thoroughness and precision, a juncture beof the recess are connected with the adjacent tween portions having their surfaces in the edges of th section 12 preferably by flash same continuous, smooth and uninterrupted welding, in order that the surfaces of the 0 plane at the said juncture. connected main body and section may be bjects of the present invention are, theremaintained at their juncture in the same unfor to provide a novel and improved process obstructed smooth plane. In order'that the f0! the manufacture 0f formable blanks havedges of section 12 may be effectively flash ing suflicient fullness at the locations of anwelded to the edges of the recess in the blank gular draws to substantially eliminate all unwithout welding imperfections at the juncdue strain on the material due to the forming ture in the finished product, the angle beof such draws, in which process flash weldtween the sides 17 and 18 of the section 12 ing may be efficiently employed for connectto be connected is of greater spread than ing the parts; and to provide an improved that between the corresponding edges of the construction in blanks of this character such recess so that the welding arc will begin opready for shaping into its eration between the portions of the section and recess adjacent the toward the apices 15 and 16. In this manner undue burning away of the metal adjacent the apices is prevented and this increased spread between the edges of the section may be so determined that when the edges meet, a perfect fit will result. The apices 15 and 16 may be slightly rounded, as shown, to the same ends. The weld is cleaned up in any known manner.

The crease or fold 13 extends from the apex 15 of the section12 to a point on the base 14 ordinarily bisecting the angle at the apex find extending in perpendicularity to the ase.

This crease is also characterized by being progressively increased in fullness from the apex where the strain in blanks of usual construction is least to the base or outer edge 14 where the strain is greatest, the increment in the fullness being proportioned at any point to the strain to be relieved. The crease may be formed either before or after the edges of the section are trimmed as niay be found expedient, and the crease or fold may be provided in any suitable manner as by being formed in dies, drawn, or folded.

The connection between the main body of the blank and the supplemental section having been made in this manner, the blank is final form which is done by the usual methods of drawing the same in dies. During the shaping of the portions at the bends as set forth above, the crease or fold in the supplemental blank will be straightened out and will assume the shape of the acute angle draw without undue strain upon or breaklng of the metal. In this manner not only is the acute angled draw more easily formed, but a neater finish of the product is produced.

It will be understood that the embodiment f the invention herein illustrated and described may be varied from the specific showing and may have a wide range of application both in the matter of material used in formation of the blank, in the position and shape of the supplemental section and in the kindof article to be formed from the blank. I do not wish to be limited, therefore, in the scope of the invention except by the state of the art and the appended claims.

What I claim is:

1. The process of connecting a supplemental section of sheet metal in a recess in the body of a blank of like material, which consists in forming said recess with relatively sharply converging edges, forming the section with edges converging at a wider angle than that between the edges of the recess, and flash welding said edges together, the flash welding proceeding 'while relatively approaching the blank and section substantialbases 14, progressing 1y along the bisector of the angle formed by said converging edges.

The process of forming a sheet metal blank having a main body and portions to be .bent therefrom at angles and in intersecting planes, which consists in shaping the blank with a recess having relatively sharply converging edges, forming a creased supplemental section with side edges converging at a wider angle than that between the edges of the recess, and flash welding the converging edges of the section to those of the recess, the flash welding proceeding while relatively approaching the blank and section along substantially the bisector of the angle formed by said converging edges.

3. The process of providing and shaping a sheet metal blank having portions bent from the main body thereof into intersecting planes, consisting in forming the main body of the blank with a recess having relatively sharply converging edges at the location of prospective intersection, filling the recess with a supplemental section of greater transverse fullness than that of the recess, and of which the edges converge at a wider angle than those of the recess, flash welding the edges of the recess and section together while relatively approaching the main body of the blank and said supplemental section substantially along the bisector of the angle formed by said converging edges, bending the said portions into intersecting planes and forming the supplemental section to the angle between said planes.

4. A formable sheet metal blank consisting of a main body portion having a recess therein with relatively sharply converging edges, a supplemental section in said recess having similar converging edges flash welded to the edges of the recess to form with the main body portion a unitary blank of substantially uniform gauge throughout, said section having greater transverse fullness than the recess.

In testimony whereof I hereunto afiix my signature.

JOHN P. TARBOX. 

